Method and apparatus for continuously producing thermoplastic organic synthetic plastic sheets having polished surfaces



E. SZANTAY May 14, 1957 7 2,791,801 METHOD AND APPARATUS FOR CONTINUOUSLY PRODUCING THERMOPLASTIC ORGANIC SYNTHETIC PLASTIC SHEETS HAVING OLISHED SURFACES 5 Sheets-Sheet 1 INVENTOR. 520/2215? MW W W JAB Filed Dec. 9, 1953 May 14, 1957 E. SZANTAY 2,791,801

METHOD AND APPARATUS FOR CONTINUQUSLY PRODUCING THERMOPLASTIC ORGANIC SYNTHETIC PLASTIC SHEETS HAVING POLISHED SURFACES 5 Sheets-Sheet 2 Filed Dec. 9, 1953 May 14, 1957 E. SZANTAY 2,791,801

METHOD AND APPARATUS FOR CONTINUQUSLY PRODUCING THERMOPLASTIC ORGANIC SYNTHETIC PLASTIC SHEETS HAVING POLISHED SURFACES 5 Sheets-Sheet 3 Filed Dec. 9, 1953- May 14, 1957 E SZANTAY 2,791,801

METHOD AND APPARATUS FOR C ONTINUOUSLY PRODUCING THERMOPLASTIC ORGANIC SYNTHETIC PLASTIC SHEETS HAVING POLISHED SURFACES Filed Dec. 9, I953 5 Shets-Sheet 4 May 14, 1957 E. SZANTAY 2,791,801

METHOD AND APPARATUS FOR CONTINUQUSLY PRODUCING THERMOPLASTIC I QRGANIC SYNTHETIC PLASTIC SHEETS HAVING POLISHED SURFACES 5 Sheets-Sheet 5 Filed Dec. 9, 1953 INVENTOR. '7 52a@ United States Fatent pCI) -METHOD AND APPARATUS FOR-CONTINUOUSLY PRODUCING THERMOPLASTIC ORGANIC SYN- THETIC PLASTIC SHEETS HAVING POLISHED SURFACES Generally, when thermoplastic organic synthetic plastic sheets are produced, by extrusion molding or other continuous processes, suchsheets do not have polished surfaces, the surfaces being somewhat rough and having a decided grain of peaks andyalleys. A number of attempts have been made in the past to provide such sheets with polished surfaces, but these attempts have not been commercially "successful. For example, inon'e such attempt, sections of the sheets have been placed against metal plates having polished surfaces, placed in apress and then heated cooled in'the' press for polishing the sheet "sections. While the polishing process, so performed, gives good results, his a batch process which is so expensive as to be commercially prohibitive. In another attempt, one directed to acentinilous'process, the sheet ha'sb'een a plied against a-polished "traveling-belt, the belt and sheetbeinfg successively heaiedand cooled for polishing purposes. This process, however, is wasteful of heat, requires the 'use of' a completel formed sheet and the polishing of the sheet hasnot been consistentl and commercially uniform.

The principal object of this invention is to provide a new andimproved'method and apparatus for 'co'nt'iiiuously producing thermoplastic organic synthetic plastic sheets having polished-surfaces, wherein a high "degree of polish -is obtained; wherein the polishingof the sheetfs eensistently and cemmerc'ianyirnirorm, wherein tlfepblishihg isae'coinplished in en-inexpensive and continuous maimer,

wherein greatesrheat econoniiesare made possible, where i in the method is simple and 'readily per formed-on a commercial basis, wherein the apparatu -'is simple anointinpensive in construction and is readily manipulated. tor

performing the process, wherein'the polishing errhe sheermay heaeeontplishedinthe same continuous "process With-the extrusion molding-of the sheet.

While in "accordance with this iimention;the sheet of thermoplastic organic synthetic plastic "may be' polished after the sheet has been completely produced, :it'iniayin accordancewith this inventio'n be polished during the production thereof, 'andftheinvention will be described here after in connection with the latter.

'Briefly, an extrusion machine mixes and plastiei'zes-ia thermoplastic organic synthetic thermoplastic m'aterial iof any desired :kind and continuously extrusion molds-the same through a suitable extrusion die as acontinuous'ly advancingsoft sheet. :A coolin-g'mechanism is locatediadjacen-t'the extinsion'die for cooling one of thesurfaces of the soft sheet, preferably, Tthe lower side. thereof. ?In "this respect, the :softslteet'passes over the cooling mechanism for cooling thatslirface of the sheet :sufiiciently to ealise the same 'to he self supporting .and formretainingrso *-as to act as a-conveyor for the sheet. Thiscooling mechanism may include-a heat conductingzplate' and shear-conducting pipes through which a cooling medium is circulated. In addition to contacting the sheet "the cooling *mecha'nism also provides a cold blanket of air for, uniformly cooling the-lowersideof thesheet;

A heating mechanism is located adjacent rthefeiitrusion dies-for heating 'the-otherisurface, -the-;upper surface, of the 2,791,801 Patented May 14, 1957 Els 2 soft'slreet. In thisre's'pect the soft sheet passes under the heating mechanism for heating that surface of the sheet sufliciently to soften the same to a plastic flow state or moldable condition. This heating mechanism may include radiant heating'means'directed at that surface of the sheet tos'often that surface.

The thermoplastic organic synthetic plastic sheet is a good insulator against heat transferand allows this differerftial"in temperature between the sheet surfaces to be maintained which in turn permits, at the same time, the lowersnrface to be'sufliciently cool to act as a conveyor "andthe u er surface to be sufficiently hot to be soft-and mold'ahle. This regulation of'the surface temperatures in manner is accomplished with a minimum heat transfer and expenditure of heating and cooling energy.

A pair of cylindrical rolls are located adjacent the 'heating andcoolingmeans and preferably'these rolls are horizontally arranged, such as in a vertical or a horizontal stack. The-roll, which is to be contacted by the soft surface of 'the sheet, is provided with a polished surface. Iiocated-adjaeent the roll with the polished surface, preferably in stacked alignment with the rolls, is acylindrical stripper roll. The sheet is passed from between-the heating and cooling mechanisms between said pair of rolls, over a portion of the "roll having the polished surface and then over the stripper roll. Thesheet is pressed between said pair of rolls and in so doing is sized as to thickne s, and is densified and compressed into a more homogeneous sheet. The 's'oft'upp'er surfaceof'the sheet which engages an appreciable portion of the polished r'oll'is molded and polished by that roll. This polished roll also cools the soft surface of the sheet being molded thereby suflici'ently to set the polished surface and permit the sheet to be stripped therefrom by the stripper roll. 'In tliis respect, the polished roll is preferably cooled in any saitahle manner 'as by circulating a cooling medium therethrough. The other of the pair of ro'llsalso may *pe'rformac'ooling operation on the sheet to regulate the rate of cooling of the sheet, and 'here alsoa cooling medium may be circulated through this roll. Since it is sheet surface temperature that is principally "being regulated'bysaid' pair of rolls only a minimum ofih'eat transfer andnexpenditure of cooling energy is here required, :although large changes in surface temperatures are produced;

At a distance from the'strippe'r-ro'll aredocated'a'pair of pulling rolls, the polished sheet extending from the stripper roll between the pulling rolls lto' -beipulled thereby. fly'thee time the-polished sheet reachejs' the pulling rolls, it has cooled considerably and is substantially completely set; Theipullingrolls, said pair of rolls iand the stripper roll are all driven at substantially thesamellinear speed as thezshee't isbeing extruded by theextrusion-die so as to maintain a desired degree of tension in'the-lsheet'between therextmrsion die and the pulling: rolls. Edge shears or routers may be provided adjacent the pulling rolls'for trimming the-edges of the sheet to uniform widths. 'Cutoff means may be provided at thedownstream endof's'the apparatus for severing -d esi'red sections :from the end of the advancing sheet.

;In'accordanc e with=th is invention, ithje other side of the sheet may also be polished, 'if-desired,,to provide -a sheet with both of :its sides polished. In this respect, the 's'tripper roll may be provided with a polished surface, another =rjoll arranged adjacent thereto and heating means pro vided for heating the unpolished 'side'of .thesheet'toa-soft moldable-condition as thesheet passes to the stripper roll. l 'he-sheet in-passing between these two rolls has its other sidepolished -in the manner discussed above. Preferably :an :additional stripper roll is provided for stripping the sheet-fr.om the polished ,stn'pper roll. ,Sinceonly'thesurfaceiof the sheet is-heated to a soft moldable condition,

3 the polished surface previously applied to the other side of the sheet will not be adversely affected by this second polishing operation.

Basically, as seen from above, this invention involves the regulation of surface temperatures of the thermoplastic organic synthetic plastic sheet, making one surface self supporting and self retaining so that it acts as a conveyor for the sheet for readily handling the same and for providing a hard backing against which pressure can be applied through the soft moldable surface to obtain the desired high polished finish thereon, making the other surface soft and moldable so that it may be molded and polished in a continuous manner by a polished roll, and reducing the surface temperature of the sheet on the polished roll to set the polished surface and allow stripping of the sheet from the polished roll. This invention may, therefore, be utilized for continuously polishing sheets which have already been completely formed or for continuously polishing sheets as they are being formed.

Further objects of this invention reside in the various steps and sequence of steps utilized in the method of this invention for producing thermoplastic organic synthetic plastic sheets with polished surfaces and in the details of construction and cooperative relationships between the component parts of the apparatus of this invention for performing the method.

Other objects and advantages of this invention will become apparent to those skilled in the art upon reference to the accompanying specification, claims and drawings, in which:

Fig. l is an illustrative view, generally in the form of a flow diagram, illustrating the method and apparatus of this invention for continuously producing thermoplastic organic synthetic plastic sheets having polished surfaces:

Fig. 1-A is a partial illustration similar to Fig. l but showing the horizontal rolls arranged in a horizontal stack rather than a vertical stack;

Fig. 2 is an enlarged sectional view through a portion a thermoplastic organic synthetic plastic sheet which has been extrusion molded;

. Fig. 2-A is a view similar to Fig. 2 but illustrating one side of the sheet being polished in accordance with this invention;

Fig. 3 is a partial illustration similar to Fig. 1 but showing the manner in which the other side of the thermoplastic organic synthetic plastic sheet may also b polished;

Fig. 3-A is a view similar to Figs. 2 and Z-A but illustrating the sheet polished on both sides;

Fig. 4 is a side elevational view of the portion of the apparatus utilized in polishing the sheet;

Fig. 5 is a top plan view of the portion. of the apparatus illustrated in Fig. 4;

Fig. 6 is an end elevational view of the apparatus looking from the right in Figs. 4 and 5;

Fig. 7 is a vertical sectional view through the roll having polished surface;

Fig. 8 is a sectional view taken substantially along the line 8-8 of Fig.7;

Fig. 9 is a horizontal plan view taken substantially along the line 99 of Fig. 4;

Fig. 10 is an enlarged sectional view taken substantially along the line 10-10 of Fig. 9;

Fig. 11 is a side elevational view of the radiant heating means with portions thereof broken away;

Fig. 12 is a vertical sectional view taken substantiall along the line 12-12 of Fig. 11;

Fig. 13 is a vertical sectional view taken substantially along the line 1313 of Fig. 11.

Referring now to the drawings and more particularly to Fig. l, the apparatus of this invention for continuously producing thermoplastic organic synthetic plastic sheets having polished surfaces is generally designated at 10. It

includes a conventional extrusion machine 11 carried by a suitable base 12. The extrusion machine 11 is provided at one end with a hopper 13 into which thermoplastic organic synthetic plastic material, in granular or like form, is fed. This material is heated and worked in the extrusion machine to plasticize the same. The other end of the extrusion machine is provided with a heated extrusion die 14 having a long, substantially horizontally arranged adjustable slot through which the plastic material is extruded in the form of a soft sheet indicated at 15. This sheet 15, when it is so extruded, is very soft and is not self supporting and form retaining.

Located adjacent to the extrusion die 14, is 'a cooling mechanism including a heat conducting plate 17 made of brass or similar material. This plate may be supported by a suitable frame 18. Resting on the plate 17 are a plurality of transversally arranged heat conducting tubes 19, such as brass tubes. Cold water is circulated through these tubes to cool the tubes and the plate. The soft sheet 15 of extruded thermoplastic organic synthetic plastic is advanced over this cooling mechanism and the lower surface of the advancing soft sheet is cooled thereby sufficiently to cause the same to be self supporting and form retaining so that this lower surface acts as a conveyor for the sheet 15.

Also located adjacent the extrusion die 14 is a heating mechanism which includes one or more radiant heating devices 20, such as commercially available Calrod units. These radiant heating devices include electrical heating elements and reflectors for directing radiant heat downwardly onto the upper surface of the advancing sheet 15. The radiant heating devices 20 heat this upper surface of the sheet sufficiently to soften the same to a plastic flow state or moldable condition. The thermoplastic organic synthetic plastic sheet 15 is a good insulator against heat transfer and it allows this differential in temperature between the sheet surfaces to be maintained which in turn permits, at the same time, the lower surface to be sufliciently cool to act as a conveyor and the upper surface to be sufficiently hot to be moldable.

Located adjacent the heating and cooling mechanisms is a frame 22 which has a pair of spaced apart uprights 23 and a pair of supporting members 24. A pair of horizontally arranged and vertically stacked cylindrical rolls 25 and 26 are journalled for rotation between the pair of uprights 23. Also journalled between the uprights 23, above the'roll 26, is a cylindrical stripper roll 27. These rolls 25, 26 and 27 are preferably hollow so that a cooling medium may be circulated therethrough. The roll 26 is provided with a highly polished surface. The radiant heating devices of the heating mechanism are adjustably supported by a pair of members 28 which in turn are carried at one end by a pair of arms 29, the radiant heating devices being supported above the advancing sheet 15.

The advancing sheet 15, after leaving the cooling and heating mechanisms, passes between the pair of rolls 25 and 26 to be pressed thereby for the purpose of sizing the sheet as to thickness. The advancing sheet 15 passes around the roll 26 having the polished surface and engages an appreciable portion thereof. The advancing sheet 15 then passes over the stripper roll 27. Since the hot upper surface of the advancing sheet 15 engages the polished surface of the roll 26 it is molded thereby into a polished condition. As the upper surface of the advancing sheet 15 so engages the polished surface of the roll 26 it is cooled thereby sufliciently to cause the polished surface to set and to allow stripping of the sheet from the roll 26 by the stripper roll 27. Preferably, a relatively cold cooling medium is circulated through the roll 26 to accomplish this cooling operation. Also, preferably a warmer cooling medium is circulated through the roll 25 for regulating the rate of cooling of the lower surface of the advancing sheet 15. The stripper roll 27 may or may not have a cooling medium circulated therethrough, depending upon the amount of cooling to be accomplished thereby.

A radiant heating means 31, similarsto the radiant net heating means 20,11is:adjustablyicarriedibyoasbracket fiz above the advancing sheet 15 as it emerges from-the stripping roll 27*; This radia ntheating devic,e 31 ':isfor the purpose of annealing-1 the: advancingsheet :15 to re-. move stresses and strains therefroms If desired, the supportingrmember 24 may carry a pluralityof pipes33 having upwardly facing holes: Air may be=supplied to these: pipesto be directed against -theunder-sid'e pf the sheet-'15 for'cooling-the same.

A frame=35-which mayor may not--be apart of-the frame 22 f carries a pair of spaceduprights 36 in which are journalled for rotation apair of pulling rolls '37 and 383 The advancing sheet 15 passes between -the-pullir'ig rolls" 37 and 38-and is-pulled-thereby. The-frameBS-finay also --be --p rovided-with edge -trimming devices such'as routersorrotary-shears =39 and\40. These edge trimming devices trim the edges-f the sheet-1510 provide a uni form width 'forthe sheet. The sheet 15='maybe supported by a supporting device 41 and may be advanced to a shearing machine 42 ha ving a shearing knife 43 for-' cutting desired sections from the end of -"the "advancing sheet 153 The shearing machine 42 maybe driven -by--a pulley 44,;belt '45 and pulley '46 driven by'an;elect-ric-motor 47 The pair of rolls' 25 and-26; the stripper roll 27;and the pulling rolls 37 and 38 are power-drivemat ,substan tially' thensame linear speed as;the rate of linear extrusion of the sheet 15 from the "extrusion die -;14in order to maintain predetermined desired-tension inthe; advancing sheet:

When the sheet 15 is extrudedfrom,theextrusionpdie 14 thessurfaices of the sheet are not'polishedilthey'being somewhat roughj-and including a grainof peaksand-vab leys as illustrated in Fig.2. However,;in' accordance withjth'is invention the upper surface of the sheet '15jiis surface molded "by the polished rollj26 to eliminate the peaks and lvalle'ys to providean extremely smoothVsur facerasillustrated in Fig. 2- A. The degree of polish im parted to the surface of'the sheet'15 depends up 'on the' typerof material formingthe sheet, the mace temperatures ofthe sheet and, the degree of polish'pnthelrollmj.

Themethod and apparatus of this invention is adapted reproduce. polished surfaces, on them-lopla'sti'ci organic synthetic sheets lof substantially all typ suof such mas terials, such as,- cellul ose.ethers such asrmethylrcell 'l los and, ethyl ycelluloseycellulose esters such as cellulose acetate, cellulose butyrate and cellulose acetate-butyrate; acrylatetand methacrylate-tpolymers andicopolymersusuch asthosetderived from methyl acryla'teand methyl metlk acrylate Wlth ;0l' .vwithout vinyl acetate,. vinyl alcohol, aerylonitrile, andthe like; polystyrene polymers iandtcoz polymers; polyvinyl resins: such as. polyvinylnchloride", polyvinyl acetal, .polyvinyl acetate, polyvinylqchlorider. acetate; polyvinylidene chloride, polyvinyl butyral, polyvinyl; alcohol, and 'copolymers of vinyltoluene... Forap ur: poses of specific, illustration-in this application, a modified polystyrene pla-stic commercially known as Don/.4715; a polyst-yrene; plastic modified with rubber, is herein -,de scribed as being produced into .a sheet form' with a polished surfacein accordance 'with this invention. The sheet so producedmay have an extrusion :thicknesslof .0807 and mayhave ;a width of-SO'K plus. The average-conditions forforming and polishing-a sheet of thisrmaterialcare substantial-1y asfollows: The machine heats Toff-the ex: trusion rnachine'lljconsist of five zones, thei -rear zone at the hopper feed opening being substantially 25.0 The average condition forgth'e production 11013;, this thickness-of 'sheet in the four (4) forward zones is, sub: stantially 360 The range of temperatures -in'the;rear zone may be from-200 F to 300 F? and theran'geeof temperatures for the four (4) forward ZOne-may'be-from 330, Fjto 440 F; The long extrusion die -14"f'orex trudingthe sheet 15 is temperature'controlledin various zones along its length; the average die temperaturebein'g substantially 400 FT The'range of the temperatures may extend from-340% 'Ff4021-420'3: Theractualrtemperatiire" of the; plastieima terial'z emerging fromstlie r-ext'msion die 11 isxsubstantial-lyi400 Fsiand:thenormahrangenflteme per-atures: of: theirmateriak'mayzzextendsfrom 340Ffv-=1' "to TheiplateilTand1he;pipesa19-:of the cooling mechanism are icooled; -by;circulatingrcoldlwaterszthrough the; pipes; The.-laverageitemperature of thezwater circulatedgthrough the pipes :isusubstantiallwGS and 'zthe :range rots-water temperatures mayzextendfrom--40iFrto-80 F. Thistcooling,=,afiorded.,by theicoolingzmechanismalowers the. tem.

peratureaofztheelower surfacerof'tthesadvancingsheet 'sub? stan'tially to; cause; the. {same :to bee self 'supporting-s'rand self retaining. .so asito act as-aconveyorufor thersheets; The averagesurface atemperature'zofathe bottom-1011.225; is sube stantially; 195 and :this' roll v is; preferably :cooled abycirculatin-g thOl'; coil: therethroughl. Thegirangecof-z surface temperatureriof: the 5101'1 25: maysextendzfroma 17 5?- F." to 21-53 Here theilimputz-temperaturesof theizhot'z-oil to the roll is substantially; 1160 :F: and :.-the-. sex-it rtemp eraturefro-m theza'ollzfis substantially .180l-'F2-. The. range of aoil imputttemperaturessmay extendifromi :1 403" t0fi190 F11 and the range of exit oil temperatures maytextendfrom 1510fF. -to;2'-l.0:"- This roll 25'rtherefdre p'rovidesadditio'nah controlled. cooling ofx-theilower:surface ofi'the:.ad vancingisheet 15. {I

Thea-heating mechanism;:;.including.:theaz-radiantrheaters 20;;101361'86840 heat the upper surfacerofz thesadvancing sheet- 15;.to ahiglntemperature of .at least the temperature ofcthermateriah .bein'g. extruded from thedie. 14, .namely,-.to at: least tsubstantially-4o0i This=- makes: the supper surface;of.theiadiIancingsheet-IS soft andrmoldableaaplass tic iiowtstatqr-forvthe subsequent polishing operation; 1 The average; surface. temperature :of- 'the -:.-roll261'havingethe polished :su'rface is -1 15? F5 This roll is preferably cooled by water, theaverageimputxtemperature :ofthe. water be:- ing 7 0? and zthe'zaverage exit temperatureof theswater being;substantially 75 The-trangepof watertemperatureslto this'iroll mayiextend-fromfiOi. to 150 1 This roll26 absorbs: suificient'iheat from the upper surface of the; sheet 15 *tDuSfl thelpolish-r on that surface andv :to allow .the, sheet-, to be strippedsfrom the roll 26*:byi the stripper: roll 27.-

For then-average condition hereunder consideration; no cooling; medium needrbescirculatedtthrough" the stripper roll. 27;,"this roll havingan average surface temperature "of substantially-r1959? F. Water. :or oil coolingrof. the? roll 2'7; mayzbe1necessaryxfonrheaviervgauge-sheets; that is; sheets heav'ienthan .080" thick: If f cooling: of the strip: per roll; Zia-is necessary,"watenorvoil maybe circulated therethrough r to :maintain a proper-average .surface-;tem.- perature range of between.;l F; and: 210;F.

After the :sheet: leaves theistripper roll and itravelsalO to a 20 feet -to.-the-1.cut-offt :mechanism it 42, the sheet.- 'has cooled c nsiderably-.-. Atsthe-cut-ofi mechanism :42 the sheet feels warm to the hand but notr-too hot tothandle bare handed.

The foregoing comparisonsof temperatures are for the particular type of thermoplasticorganic syntheticlpl astic materialspecified and for the thickness and width' of the sheet specified. For other types of plastic materials and for other thicknesses and widths different specific temperature values will be required butthe relationships between the temperature values willremainsubstantially the same.-

Fig.--1-A showsan arrangement wherein the horizontal rolls 25, 26 and 27 are-horizontally stacked as distinguished from the vertical stacking as illustratedin Pig. 1. The manner of operation of the .arrangement ofcFig. l-A is substantially'the sameqas th'aLof' Fig.1 and a furtherdetailed 'descriptionis not considered necessary; Int-the arrangement of Fig. 1 A, thexunderside of thefsheet-sl5 contacts anappreciable/portion of fthezsu-rface' of; 111621011 25 and'accordingly the roll :25: may have a'greater; cooling efiect upon that surface than is the case in Fig. 1. Thus, the roll 25 in Fig. l-A may assume a greater portion of the cooling load and thereby decrease the cooling load of the cooling mechanism including the pipes 17 and plate 19.

Fig. 3 illustrates an arrangement for also polishing the other side of the sheet 15. Here the stripper roll 27 is provided with a polished surface and radiant heating means 49 are provided for heating that surface of the sheet 15, which would engage the polished stripper roll 27, to a soft and moldable condition. Another roll 50 may be located adjacent the stripper roll 27 for pressing the sheet 15 therebetween. The sheet 15 will be molded into a polished condition by the polished stripper roll 27 and will be cooled thereby, the sheet being stripped from the polished stripper roll 27 by a stripper roll 51. Here the polished stripper roll 27 would be cooled as by circulating cold water therethrough in the same manner as in connection with the polished roll 26. In other words, the same polishing action is applied to each side of the sheet. Fig. 3-A illustrates a portion of the sheet which has been polished on both sides by the arrangement illustrated in Fig. 3.

The details of construction of the apparatus of this invention, as generally shown in Fig. l, are illustrated with more particularity in Figs. 4 to 13 of the drawings. As shown more clearly in Figs. 4, 9 and 10 the ends of the heat conducting plate 17 are provided with a plurality of pins 56 for receiving and locating the heat conducting pipes 19 extending along the plate. The ends of the pipes 19 are provided with suitable fittings 57 which in turn are connected to hoses 58 for circulating cold water through the pipes 19. The pipes 19 and plates 17, in addition to acting themselves to cool the bottom surface of the sheet 15, also operate to cool the air beneath the sheet so that the sheet is further cooled by this blanket of cold air.

The details of the heating mechanism, including the radiant heating devices 20, are shown more specifically in Figs. 4, 5, 11, 12 and 13. Here the radiant heating devices 20 are secured at their ends by screws 60 to the ends of rods 61. The rods 61 extend upwardly through angle members 64 and are provided with collars 62 and thumb screws 63 for adjustably mounting the rods 61 in the angle members 64. By manipulating the thumb screws 63, the radiant heating devices 20 may be lowered and raised with respect to the upper surface of the sheet to provide the proper amount of radiant heating thereof. The ends of the angle members 64 are adjustably secured by bolts 65 extending through slots 66 in the angle a members 28. By reason of these bolts and slots, the angle members 64 may be adjusted forwardly and rear- Wardly along the angle members 28 so as to position the radiant heating devices forwardly and rearwardly with respect to the extrusion die 14 and the pair of rolls and 26. Thus, complete adjustment of the heating devices is provided.

Secured to the ends of the angle members 28, as by means of welding, are a pair of levers 67. Bolts 68 extending through the members 67 and 28 and through a spacer 69 pivotally mount the members 28 and 67 on the uprights 23 of the apparatus. One end of a spring 70 is connected to each member 67 and the other end of each spring is connected to a member 71 secured to the uprights 23 by screws 72. The springs 70 therefore act as a counterbalancing means for the heating units 20 so that the heating units may be swung into and out of place with the greatest amount of ease. The members 29 are secured to the ends of the members 253 by bolts 74, spacers 75 and nuts 76. Secured to the top of the uprights 23, by means of bolts 78, are a pair of arms 77 which in turn carry pins 79. These pins 79 are adapted to receive one of a plurality of notches 80 in the members 29. In this way, the members 28 and the radiant heating devices 20 may be swung upwardly and latched into any desired position. 4

Referring now more particularly to Figs. 6, 7 and. 8; the details of construction of the rolls 25, 26 and 27 are illustrated. For example, the cylindrical roll 26 has a cylindrical shell whose outer surface is highly polished. The shell 26 is carried by and welded to a pair of annular members 82 which in turn are secured to and carry a pair of shaft members 83. The shaft members 83 are, centrally provided with bores 84 which communicate inside of the roll with radial bores 85. The shaft members 83 operate to journal the roll 26 for rotation in the uprights 23 and are provided at their ends with screw threaded extensions 86. One of the shaft portions '83 is provided with a portion 87 for receiving a gear as will be pointed out more fully hereafter. The rolls 25 and 27 are constructed in the same manner as the roll 26. A cooling medium may be circulated through the rolls by means of the bores 84 and 85.

Referring now more particularly to Figs. 4 and 6, the

shaft portions of the roll 25 are journaled in bearings 89 which are received in slots 90 in the uprights 23. The shaft portions of the roll 26 are journalled for rotation in bearing members 91 which are received in slots 92 in the uprights 23. Springs 93 engage each bearing member 91 for resiliently urging the roll 26 toward the roll 25, these springs 93 being backed by blocks 94 slidable in the slots 92. A pair of screws 95 engage the blocks 94 and are carried by brackets 96 secured to the uprights 23 by screws 97. By adjusting the screws 95 the tension of the springs 93 may be adjusted for regulating the resilient force moving the roll 26 toward the roll 25. In this way, the sizing of the sheet 15 as to thickness may be regulated. While the top roll 26 has been shown to be adjustable. with respect to the bottom roll 25, the reverse situation could equally as well be utilized wherein the bottom roll is adjustable with respect to the top roll. All that is necessary, is that there be a relative adjustment of the two rolls.

The shaft portions of the stripper roll 27 are provided with general bearings 99 which are slidably received in slots 98 in the uprights 23. Screws 100 extend upwardly from the bearings 99 through a screw threaded bracket 101 suitably secured to the uprights 23 and are provided at their upper ends with hand wheels 102. By rotating the hand wheels 102 the strip-per roll 27 may be raised and lowered.

One of the shaft portions of each of the rolls 25, 26 and 27 have gears 104, 105 and 106, respectively, secured thereto for the purpose of rotating the rolls. The gears 104, 165 and 106 mesh with worms 107, 108 and 109, respectively, carried by a vertical shaft 110 suitably journalled for rotation on one of the uprights 23. The lower end of the shaft 110 is provided with a gear 111 which is engaged by a worm 112 carried by a shaft 113 which is journalled for rotation on the frame 22. The outer end of shaft 113 carries a sprocket wheel 114 which is connected by a chain 115 to a sprocket wheel 116 driven by a variable speed driving mechanism 117 carried by the frame 22. When the mechanism 117 is operated, the rolls 25, 26 and 27 are power driven in the appropriate directions and the speed of rotation thereof is determined by the adjustment of the drive mechanism 117. The rolls are driven at a linear speed which is substantially the same as the rate of linear ex trusion of the sheet from the die 14.

As shown in Fig. 6, the left hand shaft portion of the roll 26 is provided with a fitting 120 which in turn is connected by a hose 121 and valve 122 to a source of cold water. The other shaft portion of the roll 26 is connected by a fitting 123 and a hose 124 for discharging water from the roll 26. In this way, water is circulated through the roll 26 for cooling the same and the rate of flow of the water may be regulated by the valve 122. In a like manner, the left shaft portion of the roll 25 is adamant provided with a 1 fitting 125 and valve 126-c0nnected T 'by -a-'hose 127 to a-source 'o'f'hot-oil. The "other shaft portion of the roll 25 is connected by a fitting 128 and a hose 129 for-dischargingoilfrom the roll '25. In this way, hot :oil is circulated through i the roll 25 for' cooling theasarne. Ihedesired amount and the rate'of tlowmay he regulated by the valve 126. The "left handshaft-porition of the stripper roll 2 7 may *be provided with-a Ifit- :ting :130 conn'ected to a "hose 121 and the right hand shaft portion thereof may be connected by a fitting 132 to aih'ose 133. Thesehoses and fittings maybe utilized i' or circulating :a cooling fiuid through the stripper roll 27 if 't-his is required.

'The radiant heatingzdevice 31 11tili'ze'd for: annealing the :sheettaaiflemerges from thestr'ipper ro'll 27may be sescored .at it-sends :to a pairof: rods 135 carried in :brackets filsecure-d to the uprights 23. The rods :may be adijustably secured to thebra'cketsIBZ in the same manner las ithe rods 61 of :the radiant heaters so that the radiant heater dl may be adjusted upwardly and downtwardly' with respect to the sheet T5 for'regulating :the amount'of heatingand .annealingiofzthe sheet thereby.

The :pu'l-lin-g '=roll -37 is suitably liournallediin bearings Z1'f37 cariied by' the frame 35 The otheri pulling roll-38 t may be journalled in bearings 138 :carrieclby levers 139 pivoted to th'e frame 35 -at Aupair of screws 1 41 :ope'rate to -position the :pulling roll 38"wit'h respect'tolthe plillin'g roll 37 so as to maintain 2a. iti'ght 'grip upon the sheet 15. The shaft carrying :the pullingirolL-S'] is pro- "vided with :a sprocket 'w heel 142 which is iconnected by a chain 143 to a sprocket wheel 144 which :istdfiVemb) awariablespeed :driving device en's. When thendevice 5 is= operated, the pulling-rolls 33.7 and :38 :are driven to pull the'sheet is. The pulling rolls 37 and 38 are driven at a linear spee'd corresponding"substantially ;to'th'e linearrate of :eittrusion of the sheet by .the .extrusion die '14 anti toa linear speed of the rolls 5, :26 :an'd=27. In' this way, proper tension is'm'aintained i-n-fthe sheet 15.

lhe a'ir pipes 33 which :may .belutilizedtfor assisting in th'e cooling of the sheet fi after .it has leftzthei stripperiroll irTqnay-be secured in place on the supporting nnembers i l'tby suitableclamping-devices 147.

While for :purposes of illustration, one form of :this invention has been disclosed, other forms ithereof may become appare'ntito those skilled in the art upon reference tothis disclosure and stherefore this invention is ".to be limite'cl only by the scope of the'iappended claims.

I claim as my-invention:

1. In a method of continuously producing :a thermoplastic organic synthetic plastic sheet having :a polished surface, the steps which :include continuously sextrusion -rnolding -a soft sheet of thermoplastic torganic synthetic plastic and advancing the same, cooling-one surface of said advancing soft sheet sufficiently toicause the same to be self supporting and form retaining to actias a conveyor for said-sheetgheating the other surface ofzsaid advancing soft sheet sufii'ciently to render said :=surface moldable, passing said advancing shee'tthetween apair of 1 cylindrical Y rolls,;on'e ofwhichis-cooledand provided :witha polished surface, to be pressed therebetween and contacting an appreciable portion of the polished surface of said cooled 'rollw'ith said moldable surface of the advancing sheet for polishing the sarne and coolingzthetsame sufficiently to enable the :sheet to be stripped from the polished-surface of 'sai'd cooled roll.

"2. In a method ofc'ontinu'ous'ly producing :a thermoplastic organic synthetic plastic :slreethaving a :polished surface, the steps which :include continuously extrusion molding substantially horizontally asoftlsheet of thermoplasticorganic synt-hetic plastic and advancing the same, cooling the lower surface of said advancing soft sheet sufficiently to cause the same to be self supporting and form're'taining to actas a conveyor-for said sheet, heating the upper surface or said advancing so'ft sheet-sufficiently to render said surface moldable, passing said advancing t sheet between. acpair of horizontal cylindricalrolls, one of which is rco'oleditandzprovided with a 'p'olished' sui fa'e,

=torbe pressed' therehetween:and contacting an appreciable :p'ortiomof said1p'0lished surface o'f the cooled roll -with the oldableuupper sui'f ace of ith'e 'advancin g' sheet' for p olishiing the-same and cooling the same-sufficiently to enahle molding asoft sheet of thermoplastic organic synthetic plastic :and advancing the same, a plying a cold blanket of :air to -one 0f the surfaces of said advancing soft sheet for cooling the same .sufiiciently tocaus'e the=sarne to he self supporting and form retain-ing :Lto :act I a conveyor forsaid sheetfiheatingthe other *surface'of said advancing :soft sheet sufliciently to Tender said surface '-In'ol'dahle, passi-ng :said advanci'ng shee't between a -pair ofcylindrical rolls, one of-which is: cooled and provided with a polished surface, to he p're'ssed therebetween and contacting an appreciable portion=of the po'lished surface of said cooled rollwith said moldablesurfa'ce of the advancing sheet for polishing the same and co'olin'g fthe s'amesufiici'ently to enab'lethe' sheetito =be stripped from =-the polished surface of said :cooledroll.

*4. In :a method of continuously producing a thermoplastic :organic synthetic plastic sheet having :a polished surface, the steps which include continuously ,rrextrusi'on m'oldinga soft sheet of thermoplastic organi'c synthetic plastic and advancing the same, cooling one *surface of said advancing so'ft sheet sufficiently to :cause the -same to {be self supporting and form retaining *to "actas a conveyor for said -sheet, applying radiant heat to i-the other snfface of said advancing so'ft she'et tb "'heatzthe *sarne sufiicientlyto'render 'said surface moldable; passing sa'id advancing sheet between apair 'of cylindrical rolls, one of which is c'ool'ed and provided 'withia spolishe'dism-- face, to bepressed"therebetween' and contacting anitappreciable portion of the polished surface of :sa'idcooled roll with said mol'd-able surface of "the advancing "sheet "for polishing "the same and 1 cooling the same sufiiciently to mblem sheet to be stripped frorn thepolishedtsun "5. 'zIn a method of continuously providing athermoplastic organic synthetic plastic sheet having a polished surface, the steps which include fc'ontinuously extrusion rnolding a s'oft sneer of Thermoplastic" organic "synthetic plastic and advancing "the same, applying :a cold "blanket of 'air' to one "of th'e surfa'c'es' of said' advan'cing soft Sheet for gcooling'ithe sante sufliciently' to cause'the" -sarne tot-be self -supporting and form retaining to "act as .a conveyor "for said sheet, applying 'radiant 'heatito *thexother surface of 'saiid advancing soft sheet toheat 'ithefsam'e sufficiently to render said sitr'face'rnoldahle, passing said advancing "s'heet between apair' of cylindrical rolls, one of which is cooled and provided with a polished suffa'ce,"to be pressed =ther'ehetween and contacting .an appreciable portion'of the polished surface of said'cooled roll withrsaid moldable -surfa'ce' of the advancing *sheet .for polishing the same and cooling the same sufiiciently to enable the sheet to be stripped from the' polishedsurface of said cooled roll.

6. In .a method of continuously producing :a thermoplastic organic 'syn'thetic plas'tic sheet having a' polished surface, the vsteps which include, continuously extrusion "molding a soft sheet of "thermoplastic organic synthetic plastic and advancing the same, passing said advancing sheetbetween a pair ofcylindrical rolls, one "of which is provided with a polishedsurface, to be pressed thereby and contacting said sheet "with-an appreciable portion ofthe roll having the polished surface, and-progressively cooling said'advancing sheet in controlled fashion by first coolingt'one surface :ofsaid soft sheet sufficiently to cause the same toz-he self supporting and form retainingltoiact as a conveyor for said sheet, prior to contact with the of said sheet, which engages the roll with the polished surface, sufficiently soft so as to be in moldable condition and be polished by the roll having the polished surface, and then cooling said other surface of the sheet as it is being polished by the polished roll surface so that it may be stripped from the roll with the polished surface.

7. In a continuous method of polishing a surface of a thermoplastic organic synthetic plastic sheet, the steps which include continuously advancing a thermoplastic organic synthetic plastic sheet, heating a surface of said advancing sheet sufiiciently to soften said surface to a moldable condition while maintaining the other surface of the sheet self supporting and form retaining to act as a conveyor for the sheet, passing said advancing sheet between a pair of cylindrical rolls, one of which is cooled and provided with a polished surface, to be pressed therebetween and contacting an appreciable portion of the polished surface of said cooled roll with said softened moldable surface of the advancing sheet for polishing the same and cooling the same sufficiently to enable the sheet to be stripped from the polished surface of said cooled roll.

8. In a continuous method of polishing a surface of a thermoplastic organic synthetic plastic sheet, the steps which include continuously advancing a thermoplastic organic synthetic plastic sheet, applying radiant heat to one of the surfaces of said advancing sheet sufliciently to soften said surface to a moldable condition while maintaining the other surface of the sheet self supporting and form retaining to act as a conveyor for the sheet, passing said advancing sheet between a pair of cylindrical rolls, one of which is cooled and provided with a polished surface, to be pressed therebetween and contacting an appreciable portion of the polished surface of said cooled roll with said softened moldable surface of the advancing sheet for polishing the same and cooling the same sufficiently to enable the sheet to be stripped from the polished surface of said cooled roll.

9. In a continuous method of polishing a surface of a thermoplastic organic synthetic plastic sheet, the steps which include continuously advancing in a substantially horizontal plane a thermoplastic organic synthetic plastic sheet, heating the upper surface of said advancing sheet sufliciently to soften said surface to a moldable condition while maintaining the lower surface of the sheet self supporting and form retaining to act as a conveyor for the sheet, passing said advancing sheet between a pair of horizontal cylindrical rolls, one of which is cooled and provided with a polished surface, to be pressed therebetween and contacting an appreciable portion of said polished surface of the cooled roll with the softened moldable upper surface of the advancing sheet for polishing the same and cooling the same sufficiently to enable the sheet to be stripped from the polished surface of said cooled roll.

10. In an apparatus for continuously polishing a surface of an advancing thermoplastic organic synthetic plastic sheet, a frame, a pair of closely adjacent cylindrical rolls, the surface of one of which is polished, a cylindrical stripper roll adjacent said roll having the polished surface, means for rotatably mounting the rolls on the frame, the advancing thermoplastic organic syningniedium to the roll having the polished surface for 12 polishing the softened moldable surface of the sheet and for cooling the same sufliciently to be stripped therefrom by the stripper roll.

11. In an apparatus for continuously polishing a surface of an advancing thermoplastic organic synthetic plastic sheet, a frame, a pair of closely adjacent cylindrical rolls, the surface of one of which is polished, a cylindrical stripper roll adjacent said roll having the polished surface, means for rotatably mounting the rolls on the frame, the advancing thermoplastic organic synthetic plastic sheet passing between said pair of rolls to be pressed thereby, over a substantial portion of the roll having the polished surface and over the stripper roll, means for adjustably positioning the rolls of said pair of rolls with respect to each other for adjustably sizing the sheet passing therebetween, radiant heating means carried by the frame adjacent said roll having the polished surface for heating the surface of the sheet, before it engages the roll having the polished surface, sufficiently to soften the same to a moldable condition while maintaining the other surface of the sheet self supporting and form retaining to act as a conveyor for the sheet, means for adjusting the radiant heating means to regulate the amount of heating of the surface of the sheet thereby, means for supplying a cooling medium to the roll having the polished surface for polishing the softened moldable surface of the sheet and for cooling the same suificiently to be stripped therefrom by the stripper roll, and means for regulating the cooling medium supplied to the roll having the polished surface for regulating the amount of cooling thereof.

12. In an apparatus for continuously producing a thermoplastic organic synthetic plastic sheet having a polished surface, an extrusion machine having an extrusion die for continuously extrusion molding substantially horizontally a soft thermoplastic organic synthetic plastic sheet, a cooling mechanism adjacent the extrusion die over which the soft sheet passes for cooling the under surface of the sheet sufliciently to cause the same to be self supporting and form retaining to act as a conveyor for said sheet, a heating mechanism adjacent the extrusion die under which the soft sheet passes for heating the upper surface of the sheet sufiiciently to render the upper surface moldable, a pair of horizontal cylindrical rolls rotatably mounted adjacent the heating and cooling mechanism, one of the rolls having a polished surface, a cylindrical stripper roll rotatably mounted adjacent said pair of rolls, said sheet passing from between the heating and cooling mechanisms between said pair of rolls, over a portion of the roll having the polished surface and over the stripper roll, said sheet being pressed between said pair of rolls and the moldable surface of said sheet being polished by the roll having the polished surface and cooled thereby sutficiently to be stripped therefrom by the stripper roll.

13. In an apparatus for continuously producing a thermoplastic organic synthetic plastic sheet having a polished surface, an extrusion machine having an extrusion die for continuously extrusion molding substantially horizontally a soft thermoplastic organic synthetic plastic sheet, a cooling mechanism adjacent the extrusion die over which the soft sheet passes for cooling the under surface of the sheet sufiiciently to cause the same to be self supporting and form retaining to act as a conveyor for said sheet, heating mechanism adjacent the extrusion die under which the soft sheet passes for heating the upper surface of the sheet sufficiently 'to render the upper surface moldable, a pair of horizontal cylindrical rolls rotatably mounted adjacent the heating and cooling mechanism, one of the rolls having a polished surface, a cylindrical stripper roll rotatably mounted adjacent said pair of rolls, said sheet passing from between the heating and coolingmechanisms between said pair of rolls, over a portion of the roll having the polished surface and over the stripper roll, said sheet being pressed between said pair of rolls and the moldable surface of said sheet being polished by the roll having the polished surface and cooled thereby sutficiently to be stripped therefrom by the stripper roll, a pair of pulling rolls, said sheet extending from the stripper roll to the pair of pulling rolls to be pulled thereby, and means for driving said rolls at a linear speed corresponding substantially to the linear extrusion rate of the extrusion machine to maintain a substantially fixed tension in the sheet as it passes through the apparatus.

14. In an apparatus for continuously producing a thermoplastic organic synthetic plastic sheet having a polished surface, an extrusion machine having an extrusion die for continuously extrusion molding substantially horizontally a soft thermoplastic organic synthetic plastic sheet, a cooling mechanism adjacent the extrusion die over which the soft sheet passes for cooling the under surface of the sheet sufiiciently to cause the same to be self supporting and form retaining to .act as a conveyor for said sheet, a heating mechanism adjacent the extrusion die under which the soft sheet passes for heating the upper surface of the sheet sufficiently to render the upper surface moldable, a pair of horizontal cylindrical rolls rotatably mounted adjacent the heating and cooling mechanisms, one of the rolls having a polished surface, a cylindrical stripper roll rotatably mounted adjacent said pair of rolls, said sheet passing from between the heating and cooling mechanisms between said pair of rolls, over a portion of the roll having the polished surface and over the stripper roll, said sheet being pressed between said pair of rolls and the moldable surface of said sheet being polished by the roll having the polished surface and cooled thereby sufficiently to be stripped therefrom by the stripper roll, a pair or pulling rolls, said sheet extending from the stripper roll, to the pair of pulling rolls to be pulled thereby, means for driving said rolls at a linear speed corresponding substantially to the linear extrusion rate of the extrusion machine to maintain a substantially fixed tension in the sheet as it passes through the apparatus, and cut-off means for severing sections from the end of the advancing sheet.

15. In an apparatus for continuously producing a thermoplastic organic synthetic plastic sheet having a polished surface, an extrusion machine having an extrusion die for continuously extrusion molding substantially horizontally a soft thermoplastic organic synthetic plastic sheet, a cooling mechanism adjacent the extrusion die, including a heat conducting plate and heat conducting pipes having a cooling medium circulating therethrough, over which the soft sheet passes for cooling the under surface of the sheet sufiiciently to cause the same to be self supporting and form retaining to act as a conveyor for said sheet, a heating mechanism adjacent the extrusion die under which the soft sheet passes for heating the upper surface of the sheet sufficiently to render the upper surface moldable, a pair of horizontal cylindrical rolls rotatably mounted adjacent the heating and cooling mechanisms, one of the rolls having a polished surface, a cylindrical stripper roll rotatably mounted adjacent said pair of rolls, said sheet passing from between the heating and cooling mechanisms between said pair of rolls, over a portion of the roll having the polished surface and over the stripper roll, said sheet being pressed between said pair of rolls and the moldable surface of said sheet being polished by the roll having the polished surface and cooled thereby sufficiently to be stripped therefrom by the stripper roll.

16. In an apparatus for continuously producing a thermoplastic organic synthetic plastic sheet having a polished surface, an extrusion machine having an extrusion die for continuously extrusion molding substantially horizontally a soft thermoplastic organic synthetic plastic sheet, a cooling mechanism adjacent the extrusion die over which the soft sheet passes for cooling the under surface of the sheet sufliciently to cause the same to be self supporting and form retaining to act as a conveyor for said sheet, a heating mechanism adjacent the extrusion die, including radiant heating means, under which the soft sheet passes for heating the upper surface of the sheet sufficiently to render the upper surface moldable, a pair of horizontal cylindrical rolls rotatably mounted adjacent the heating and cooling mechanisms, one of the rolls having a polished surface, a cylindrical stripper roll rotatably mounted adjacent said pair of rolls, said sheet pas-sing from between the heating and cooling mechanisms between said pair of rolls, over a portion of the roll having the polished surface and over the stripper roll, said sheet being pressed between said pair of rolls and the moldable surface of said sheet being polished by the roll having the polished surface and cooled thereby sufiiciently to be stripped therefrom by the stripper roll.

17. In a method of continuously producing a thermoplastic organic synthetic plastic sheet having a polished surface, the steps which include continuously extrusion molding a soft sheet of thermoplastic organic synthetic plastic and advancing the same, changing the relative temperatures of the opposite surfaces of said advancing sheet whereby one surface will be made self supporting and form retaining to act as a conveyor for said sheet and whereby the other surface will be rendered moldable, passing said advancing sheet between a pair of cylindrical rolls, one of which is cooled and provided with a polished surface, to be pressed therebetween and contacting an appreciable portion of the polished surface of said cooled roll with said moldable surface of the advancing sheet for polishing the same and cooling the same sufficiently to enable the sheet to be stripped from the polished surface of said cooled roll.

18. In a continuous method of polishing a surface of a thermoplastic organic synthetic plastic sheet, the steps which include continuously advancing a thermoplastic organic synthetic plastic sheet, producing differential temperatures between the opposite surfaces of the sheet to cause the cooler one of the surfaces to present a hard backing for the sheet and to cause the hotter one of the surfaces to soften to a moldable condition, passing said advancing sheet between a pair of cylindrical rolls, one of which is cooled and provided with a polished surface, with an appreciable portion of the polished surface of the cooled roll being contacted by the softened moldable surface of the advancing sheet, whereby pressure is applied through the soft moldable surface of the sheet to densify and size the sheet and polish the soft moldable surface of the sheet and cool the same sufiiciently to enable the sheet to be stripped from the polished surface of the cooled roll.

References Cited in the file of this patent UNITED STATES PATENTS 2,551,005 Johnson May 1, 1951 2,551,966 Pierce May 8, 1951 2,574,588 Piperoux et al Nov. 13, 1951 

